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Mitsubishi Evo 5 1998 1999 Workshop Service Repair Manual

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Welcome to the comprehensive service and repair manual for the Lancer Evolution V (Evo 5), model code CP9A, produced between 1998 and 1999. As a fifth-generation iteration of the legendary...
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Mitsubishi Evo 5 1998 1999 Workshop Service Repair ManualMitsubishi Evo 5 1998 1999 Workshop Service Repair ManualMitsubishi Evo 5 1998 1999 Workshop Service Repair ManualMitsubishi Evo 5 1998 1999 Workshop Service Repair Manual
Welcome to the comprehensive service and repair manual for the Lancer Evolution V (Evo 5), model code CP9A, produced between 1998 and 1999. As a fifth-generation iteration of the legendary Lancer Evolution lineage, this performance compact sedan is renowned for its rally homologation heritage and advanced technical capabilities. The Evo 5 builds upon its predecessors with a wider track, flared bodywork, improved aerodynamics, and a more robust chassis, all designed to deliver exceptional on-road and track performance. Its engineering quality is underscored by the potent 4G63T turbocharged engine, sophisticated All-Wheel Drive system with Active Yaw Control (AYC), and high-performance braking components, making it a highly sought-after vehicle for enthusiasts and performance driving. This manual provides extensive workshop service and repair information, covering all essential systems of your Lancer Evolution V. Within these pages, you will find detailed procedures for routine maintenance, engine and transmission overhauls, drivetrain component servicing, suspension and brake system repairs, and electrical diagnostics. It includes crucial technical specifications, torque values, special tool identification, and comprehensive wiring diagrams, all presented in English. The purpose of this manual is to empower owners, mechanics, and technicians with the knowledge required to maintain, diagnose, and repair the Evo 5 accurately and efficiently, ensuring its optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution V (Evo 5)
Model Code:
CP9A
Generation:
Fifth Generation
Production Years Covered:
1998-1999
👋 Introduction
Market Position
Vehicle Segment:
Performance Compact Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, tuners, rally drivers, and owners requiring in-depth service knowledge
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale
Key Features
Vehicle Type:
AWD Turbocharged Performance Sedan
Rally Heritage:
Homologated for Group A rally racing, built for extreme performance and durability
Technical Advancements:
Advanced AYC system, robust powertrain, upgraded chassis and braking compared to earlier Evos
Manual Value
Primary Benefit:
Enables owners and technicians to perform all necessary maintenance, diagnostics, and repairs correctly and efficiently.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Page Count
Estimated Pages:
Hundreds (Exact count varies by compilation, but extensive)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
4G63T DOHC (2.0L Turbocharged)
Powertrain:
Engine, Clutch, Transmission (Manual & Automatic Variants), Differentials (Front, Center, Rear)
Drivetrain:
All-Wheel Drive (AYC - Active Yaw Control), Driveshafts, Axles
Suspension:
Front McPherson Strut, Rear Multi-link, Springs, Dampers, Bushings, Anti-roll Bars
Brakes:
Front Brembo Ventilated Discs, Rear Solid Discs, ABS (Anti-lock Braking System)
Steering:
Power Rack and Pinion
Electrical:
Battery, Charging System, Ignition System, Lighting, Gauges, ECUs, Wiring Diagrams
Fuel System:
Fuel Injection (MPI), Fuel Pump, Injectors, Fuel Pressure Regulator, Fuel Tank
Cooling System:
Radiator, Fan, Water Pump, Thermostat, Coolant Passages
Exhaust System:
Exhaust Manifold, Catalytic Converter, Muffler
Body And Frame:
Chassis, Body Panels, Doors, Hood, Trunk, Bumpers, Glass
Interior:
Seats, Dashboard, Trim, HVAC System (Heating, Ventilation, Air Conditioning)
Diagnostics:
Troubleshooting guides, DTCs (Diagnostic Trouble Codes), Repair procedures
Procedures Included
Maintenance:
Routine service, oil changes, filter replacements, spark plug replacement, timing belt inspection/replacement
Repair:
Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, electrical system repair
Diagnostics And Troubleshooting:
Step-by-step diagnostic flows for various symptoms and fault codes
Specifications:
Torque specifications, clearances, fluid capacities, diagnostic values
Special Tools:
Identification of necessary special tools for specific repairs
Wiring Diagrams:
Detailed electrical schematics for all systems
Technical Depth
Depth:
Comprehensive factory-level repair and maintenance information
Detail Level:
Detailed step-by-step instructions, exploded diagrams, component identification
Diagnostic Capability:
Advanced diagnostics for engine management, AYC system, and other electronic controls
Rebuild Procedures:
Complete engine and transmission overhaul procedures
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content (OCR'd PDF)
Print Quality
Quality:
High-resolution, suitable for printing individual pages or the entire manual
Binding Type
Binding Type For Printed:
N/A (Digital PDF download, user prints and binds)
Paper Type
Paper Type For Printed:
N/A (Digital PDF download, user prints on desired paper)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Ps:
280 PS (JDM Spec), approximately 276 hp (DIN)
Torque Nm:
352 Nm (260 lb-ft) at 3000 RPM (JDM Spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (High Octane Recommended)
Engine Management
ECU:
Engine Control Unit (ECU) with direct ignition
Turbocharger
Turbo Model:
TD05HR-16G
Engine Internals
Piston Type:
Forged
Connecting Rods:
Forged
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (Getrag G5M-R or similar Mitsubishi F5MXX)
Optional
Transmission Type Optional:
4-speed Automatic (Less common for performance variants)
Features
Gear Ratios:
Specific gear ratios provided in manual
Fluid Specifications
Manual Transmission Fluid:
GL-4 or GL-5 SAE 75W-90 Gear Oil (Verify specific Mitsubishi recommendation)
Automatic Transmission Fluid:
Dexron III or equivalent (for automatic variants)
📐 Dimensions
Exterior
Length:
Approx. 4,350 mm (171.3 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,370 kg (3,020 lbs) for GSR model
Gross Vehicle Weight Rating:
Refer to vehicle placard or manual
🛡️ Safety Features
Ratings
Crash Test Ratings:
Limited official crash test data from independent agencies during its era; primarily designed for motorsport homologation.
Active Features
AWD System:
Advanced All-Wheel Drive with Active Yaw Control (AYC) for enhanced stability and cornering
ABS:
Anti-lock Braking System (ABS) standard
Passive Features
Airbags:
Driver and Passenger Airbags (Standard)
Seatbelts:
3-point seatbelts with pretensioners
Chassis Design:
Reinforced chassis for rally homologation
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM Radio with CD Player or Cassette Player (OEM unit)
Navigation:
N/A (Navigation systems were not standard or widely available in this era for this model)
Driver Assistance
Traction Control:
Limited to AWD system; no electronic traction control in the modern sense beyond ABS.
Connectivity
Bluetooth:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 km (3,000-4,500 miles) or 6 months, more frequent under hard driving.
Timing Belt Replacement:
Recommended every 90,000-100,000 km (55,000-60,000 miles) or 7 years, whichever comes first.
Spark Plug Replacement:
Refer to manual for specific type and interval, typically iridium plugs
Fluid Specifications
Engine Oil Specification:
API SG or higher, ACEA A2/A3, SAE 10W-30 or 10W-40 (check manual for exact spec based on climate).
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 (Verify manual for preference)
Known Issues
Engine Wear:
Piston ring wear, connecting rod bearing failure (especially if modified or poorly maintained), head gasket failure
Turbocharger:
Oil seal failure, bearing wear leading to oil consumption or turbo failure
Ayc System:
Pump failure, sensor issues, fluid leaks
Rust:
Common in older vehicles, particularly in areas prone to corrosion (wheel arches, sills, floor pans)
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi has a strong heritage in rallying, including multiple WRC manufacturer and driver championships.
Model Evolution
Evo V Development:
Evo 5 was a significant redesign with wider track, flared arches, improved aerodynamics, and stiffer chassis compared to Evo 4.
Key Changes From Evo 4:
Wider body, larger front bumper vents, improved intercooler, larger spoiler, stiffer suspension, thicker anti-roll bars.
Production
Production Location:
Japan
Market Availability:
Primarily for Japanese Domestic Market (JDM), with limited official exports to select markets; many imported unofficially.
🏆 Awards & Recognition
Recognitions
Rally Accolades:
The Lancer Evolution platform, including the Evo 5's lineage, is widely recognized for its dominance in motorsport, particularly rallying.
Enthusiast Appreciation:
Consistently ranked as one of the most desirable and iconic JDM performance cars of its era.
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